CA1165967A - Process for casting metals, using sand-moulds in the form of shells - Google Patents
Process for casting metals, using sand-moulds in the form of shellsInfo
- Publication number
- CA1165967A CA1165967A CA000384792A CA384792A CA1165967A CA 1165967 A CA1165967 A CA 1165967A CA 000384792 A CA000384792 A CA 000384792A CA 384792 A CA384792 A CA 384792A CA 1165967 A CA1165967 A CA 1165967A
- Authority
- CA
- Canada
- Prior art keywords
- moulds
- sand
- process according
- quenched
- quenching
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
Abstract
ABSTRACT OF THE DISCLOSURE
The present invention relates to a process for casting metal, using one or more sand-moulds in the form of shells solidified by a chemical reaction, characterized in that the outer surfaces of said moulds are quenching-medium-repellent, and the said shells, containing molten metal, are quenched from the outside with a suitable quenching medium in the form of a liquid or a vapour, either during the filling operation thereof or shortly thereafter.
The present invention relates to a process for casting metal, using one or more sand-moulds in the form of shells solidified by a chemical reaction, characterized in that the outer surfaces of said moulds are quenching-medium-repellent, and the said shells, containing molten metal, are quenched from the outside with a suitable quenching medium in the form of a liquid or a vapour, either during the filling operation thereof or shortly thereafter.
Description
ci5~
The invention relates to a method for casting metals, using sand-moulds in the form of shells solidified by a chemical reaction, in particular the use of this process for iron-metals, and also a casting unit suitable for the execution of the said process.
Large numbers of such casting processes are known, but many of them have processing and metallurgical disad- t vantages.
Methods are also known for cooling permanent metal moulds by means of integral cooling ducts, as disclosed in Swiss Patent 557 209, for example. A cooling method of this klnd cannot, however, be used for sand-moulds.
The present invent~on provides for casting metals using one or more moulds ~ the form of shells solidified by a chemical reaction, wherein the outer surfaces of the sand~shells are ~uenching-medium~repellent (ie. rendered repellent by a suitable suhstance ~hich repels the quenching medium). The assembled moulds are subjected to a filling operation i.e. ~illed with molten metal. The shells containing molten metal are ~uenched from the outside with a suitable quenching medium in the form of a liquid or a vapour, either during the filling operation thereof or shortly thereafter.
The process of the present invention may be used for iron-metals, prefera~ly types of gxey cast iron which solidify graphitically,castironshaving nodular graphite, and light melts (e.g. light alloy melts), preferably aluminium magnesium or alloys thereof.
In accGrdance w~th another aspect of the present invention there is~provided a casting unit for the execution of the above defined process characterized in that said unit comprisesa qucnching station, e.g. with a mask removal device, ~.16~
wherein said moulds with casting therein, are quenched during the filling operation or immediatly or shortly after casting.
The casting unit in accordance with the present invention may additionally include an impregnation station for impregnating the sand-moulds with a substance which is quenching~medium-repellent (i.e. to render mould quenching medium-repellent).
The present invention alleviates the problem of forming a load-carryin~ edge-shell rapidly in the solidifying metal mould and of producing a finely granular structure.
Particularly, in the case of iron which solidifies graphiti-cally, the additional volume produced by the separation of graphite is to be used in an inwardly directed manner to compensate for the solidification-volume deficit.
Essential to the invention, in this connection, is that the outer surfaces of the sand-moulds be impregnated with a substance which repels the guenching medium e.g., a water-repellent subst~nce, for example silicone, whereby during the fillingoperation, or shortly thereafter, the shells filled with metal may be quenched from the outside e.g. by means of liqui~ Water and/or water-vapour, without any o the quenching fluid penetrating through the sand-moulds (masks) into the iron.
The advantages of the invention are to be perceived mainly in that, especially in the case of iron which solidifies graphitically, the above-mentioned volume-compensa-tion makes feederless casting possible and, in the case of aluminum and alloys thereof, the f~rmation of gas-bubbles from the metal can be eliminated. Feederless casting means a higher yield of metal and thus a more economical operation.
In addition to t~e above-mentioned advantages, quenching of the castings according to the invention produces 3~6 ~
a significant improvement in mechanical properties.
In the case of the aluminum alloy G AlSi 8 Cu 3 cast conventionally in green and, DIN 1725 requires, in the cast condition, a tensile strength of 140 Njmm2 with a 0,5 elongation.
The process according to the invention produces, in the cast condition a tensile strength of l90 N/mm2 with 2%
elongation and, after cold-storage, a tensile strength of 210 1~/mm2 with about 2.5~ elongation.
If the masks are removed in the water, further improvement is possible, up to about 300 N/mm2 with 3,5%
elongation. Values of ~his kind can otherwise be obtained only by die-casting.
However, the invention ofers costs advantages over die-casting since it eliminates costly pressure-casting dies.
The excellent mechanical properties obtained with the process according to the invent:ion, similar to those obtained with die-casting, are attributable to the ~act that, on the onehand, the rapid dissipation of heat produces a fine-grained structure and, on the other hand, as in die-casting, the mixed crystal enriched, after cooling, with alloying additives, rema~ins in part in the super-saturated condition, depending upon the cooling rate, and thus possesses a certain age-hardening ability.
The masks may be produced, by a chemical reaction in accordance with the prior art, for example by mixing wlth the sand a bonding agent which hardens. Suc~ a process is the CRONi~NGprocess in which phenolic resins are used to bond the sand.
The wàlls of the shells are preerably at least 3 mm in thickness. The shell-like parts of the mould are made up ~5~7 as usual into a casting mould, the impregnation, ~ith sili~
cone for example, being carried out prior to assembly, but preferably after assembly, in order to avoid untreated areas in the contact surface between the shells.
The sand-masks may be flushed or sprayed with quenching fluid or vapour in the supported or unsupported condition, or may be completely im~ersed in a quenching bath. W`ater or water-vapour are preferably used as the quenching agent or medium.
The time at which the water is added depends upon the metal cast and the wall-thickness of the casting. In the case of aluminum, or very thin-walled iron castings, for example connecting-rods, the mould may be watered during casting. In the case of parts having thicker walls, for example crankshafts, water is added a few seconds after casting~
Tn the case of thick-walled iron castings, it is desirable to support the mask, Eor example as in Swiss Patent 492 493, b~cause of the solidifica~ion pressure arising and the higher thermal stressing.
The ollowing are particularly suitable as means of support~ stee~ s~otr qUartZ grit, or quartz sand and other granular material, or even solid supports.
In addition to this, in a closed container, the quenching agent itself may be used as a means of support.
If the cooling agent is removed while the masks are at a temperature of between 600 and 700, the said masks soak through to a greater or lesser extent and collapse upon being dismantled. As an alternative, the masks may be removed in the water-bath or during spraying with the quenching agent, and this has the following advantages:
a) increased ~uenchin~ effect b) the masks may be re-us.ed c) elimination of the formation of toxic decom-position-gases from the organic bonding agents used, e g. phenolic resin, during casting and after removal of the cooling agent.
As indicated in Table 1 of Swiss Patent 583 758, a phenol-formaldehyde bonding agent releases, upon being heated to the casting temperature, not only between 20 and 25% of methane, but also between 25 and 30%.of carbon-monoxide, which is very danyerous for human beings.
Thè advantage mentioned under c) above is obtained only if ths mask is quenched at temperature below the decomposition temperature of phenolic resin (about 300C).
.. - 5 -
The invention relates to a method for casting metals, using sand-moulds in the form of shells solidified by a chemical reaction, in particular the use of this process for iron-metals, and also a casting unit suitable for the execution of the said process.
Large numbers of such casting processes are known, but many of them have processing and metallurgical disad- t vantages.
Methods are also known for cooling permanent metal moulds by means of integral cooling ducts, as disclosed in Swiss Patent 557 209, for example. A cooling method of this klnd cannot, however, be used for sand-moulds.
The present invent~on provides for casting metals using one or more moulds ~ the form of shells solidified by a chemical reaction, wherein the outer surfaces of the sand~shells are ~uenching-medium~repellent (ie. rendered repellent by a suitable suhstance ~hich repels the quenching medium). The assembled moulds are subjected to a filling operation i.e. ~illed with molten metal. The shells containing molten metal are ~uenched from the outside with a suitable quenching medium in the form of a liquid or a vapour, either during the filling operation thereof or shortly thereafter.
The process of the present invention may be used for iron-metals, prefera~ly types of gxey cast iron which solidify graphitically,castironshaving nodular graphite, and light melts (e.g. light alloy melts), preferably aluminium magnesium or alloys thereof.
In accGrdance w~th another aspect of the present invention there is~provided a casting unit for the execution of the above defined process characterized in that said unit comprisesa qucnching station, e.g. with a mask removal device, ~.16~
wherein said moulds with casting therein, are quenched during the filling operation or immediatly or shortly after casting.
The casting unit in accordance with the present invention may additionally include an impregnation station for impregnating the sand-moulds with a substance which is quenching~medium-repellent (i.e. to render mould quenching medium-repellent).
The present invention alleviates the problem of forming a load-carryin~ edge-shell rapidly in the solidifying metal mould and of producing a finely granular structure.
Particularly, in the case of iron which solidifies graphiti-cally, the additional volume produced by the separation of graphite is to be used in an inwardly directed manner to compensate for the solidification-volume deficit.
Essential to the invention, in this connection, is that the outer surfaces of the sand-moulds be impregnated with a substance which repels the guenching medium e.g., a water-repellent subst~nce, for example silicone, whereby during the fillingoperation, or shortly thereafter, the shells filled with metal may be quenched from the outside e.g. by means of liqui~ Water and/or water-vapour, without any o the quenching fluid penetrating through the sand-moulds (masks) into the iron.
The advantages of the invention are to be perceived mainly in that, especially in the case of iron which solidifies graphitically, the above-mentioned volume-compensa-tion makes feederless casting possible and, in the case of aluminum and alloys thereof, the f~rmation of gas-bubbles from the metal can be eliminated. Feederless casting means a higher yield of metal and thus a more economical operation.
In addition to t~e above-mentioned advantages, quenching of the castings according to the invention produces 3~6 ~
a significant improvement in mechanical properties.
In the case of the aluminum alloy G AlSi 8 Cu 3 cast conventionally in green and, DIN 1725 requires, in the cast condition, a tensile strength of 140 Njmm2 with a 0,5 elongation.
The process according to the invention produces, in the cast condition a tensile strength of l90 N/mm2 with 2%
elongation and, after cold-storage, a tensile strength of 210 1~/mm2 with about 2.5~ elongation.
If the masks are removed in the water, further improvement is possible, up to about 300 N/mm2 with 3,5%
elongation. Values of ~his kind can otherwise be obtained only by die-casting.
However, the invention ofers costs advantages over die-casting since it eliminates costly pressure-casting dies.
The excellent mechanical properties obtained with the process according to the invent:ion, similar to those obtained with die-casting, are attributable to the ~act that, on the onehand, the rapid dissipation of heat produces a fine-grained structure and, on the other hand, as in die-casting, the mixed crystal enriched, after cooling, with alloying additives, rema~ins in part in the super-saturated condition, depending upon the cooling rate, and thus possesses a certain age-hardening ability.
The masks may be produced, by a chemical reaction in accordance with the prior art, for example by mixing wlth the sand a bonding agent which hardens. Suc~ a process is the CRONi~NGprocess in which phenolic resins are used to bond the sand.
The wàlls of the shells are preerably at least 3 mm in thickness. The shell-like parts of the mould are made up ~5~7 as usual into a casting mould, the impregnation, ~ith sili~
cone for example, being carried out prior to assembly, but preferably after assembly, in order to avoid untreated areas in the contact surface between the shells.
The sand-masks may be flushed or sprayed with quenching fluid or vapour in the supported or unsupported condition, or may be completely im~ersed in a quenching bath. W`ater or water-vapour are preferably used as the quenching agent or medium.
The time at which the water is added depends upon the metal cast and the wall-thickness of the casting. In the case of aluminum, or very thin-walled iron castings, for example connecting-rods, the mould may be watered during casting. In the case of parts having thicker walls, for example crankshafts, water is added a few seconds after casting~
Tn the case of thick-walled iron castings, it is desirable to support the mask, Eor example as in Swiss Patent 492 493, b~cause of the solidifica~ion pressure arising and the higher thermal stressing.
The ollowing are particularly suitable as means of support~ stee~ s~otr qUartZ grit, or quartz sand and other granular material, or even solid supports.
In addition to this, in a closed container, the quenching agent itself may be used as a means of support.
If the cooling agent is removed while the masks are at a temperature of between 600 and 700, the said masks soak through to a greater or lesser extent and collapse upon being dismantled. As an alternative, the masks may be removed in the water-bath or during spraying with the quenching agent, and this has the following advantages:
a) increased ~uenchin~ effect b) the masks may be re-us.ed c) elimination of the formation of toxic decom-position-gases from the organic bonding agents used, e g. phenolic resin, during casting and after removal of the cooling agent.
As indicated in Table 1 of Swiss Patent 583 758, a phenol-formaldehyde bonding agent releases, upon being heated to the casting temperature, not only between 20 and 25% of methane, but also between 25 and 30%.of carbon-monoxide, which is very danyerous for human beings.
Thè advantage mentioned under c) above is obtained only if ths mask is quenched at temperature below the decomposition temperature of phenolic resin (about 300C).
.. - 5 -
Claims (30)
1. A process for casting metal, using one or more sand-moulds in the form of shells solidified by a chemical reaction, characterized in that the outer surfaces of said moulds are quenching-medium-repellent, and the said shells, containing molten metal, are quenched from the outside with a suitable quenching medium in the form of a liquid or a vapour, either during the filling operation thereof or shortly there_ after.
2. A process for casting metal, using one or more sand moulds in the form of shells solidified by a chemical reaction, characterized in that the outer surfaces of said moulds are water-repellent, and the said shells, containing molten metal, are quenched from the outside with a suitable quenching medium in the form of a liquid or a vapour, either during the filling operation thereof or shortly thereafter.
3. A process according to either one of claims 1 and 2 wherein the metal to be cast is an iron-metal or a light metal.
4. A process according to either one of claims 1 and 2 wherein the metal to be cast is a gray cast iron which solidifies graphitically, a cast iron having nodular graphite, aluminium, or alloy of aluminium, magnesium or a magnesium alloy.
5. A process according to claim 2 characterized in that the quenching medium, in the form of liquid or vapour, is water.
6. A process according to claim 1, characterized in that the entire said sand-moulds are flushed over with the quenching medium.
7. A process according to claim 5, characterized in that the entire said sand-moulds are flushed over with the quenching medium.
8. A process according to claim 1, characterized in that said sand-moulds are sprayed with the quenching medium.
9. A process according to claim 5, characterized in that said said moulds are sprayed with the quenching medium.
10. A process according to claim 8, characterized in that the quenching medium is applied in the form of a vapour.
11. A process according to claim 9, characterized in that the quenching medium is applied in the form of a vapour.
12. A process according to claim 2, for aluminium or very thin-walled cast-iron castings characterized in that said sand-moulds are flushed with quenching agent during the filling operation.
13. A process according to anyone of claims 7, 9 and 11, for aluminium or very thin-walled cast iron castings, characterized in that said sand-moulds are flushed with quenching agent during the filling operation.
14. A process according to claim 2, for thick-walled iron castings, characterized in that said sand moulds are quenched a few seconds after the filling operation.
15. A process according to any one of claims 7, 9 and 11, for thick-walled iron castings, characterized in that said sand-moulds are quenched a few seconds after the filling operation.
16. A process according to any one of claims 2, 12 and 14, characterized in that said sand-moulds are quenched at temperatures below the decomposition temperature of the chemical bonding agent.
17. A process according to anyone of claims 7, 9 and 11, for aluminium or very thin-walled cast iron castings, characterized in that said sand-moulds are flushed with quenching agent during the filling operation and in that said sand-moulds are quenched at temperatures below the decomposition temperature of the chemical bonding agent.
18. A process according to any one of claims 7, 9 and 11, for thick-walled iron castings, characterized in that said sand-moulds are quenched a few seconds after the filling operation and in that said sand-moulds are quenched at temperatures below the decomposition temperature of the chemical bonding agent.
19. A process according to any one of claims 2, 12 and 14 characterized in that said sand-moulds, hardened with phenolic resin, are quenched at below 300°C.
20. A process according to anyone of claims 7, 9 and 11, for aluminium or very thin-walled cast iron castings, characterized in that said sand-moulds are flushed with quenching agent during the filling operation and in that said sand-moulds, hardened with phenolic resin, are quenched at below 300°C.
21. A process according to any one of claims 7, 9 and 11, for thick-walled iron castings, characterized in that said sand-moulds are quenched a few seconds after the filling operation and in that said sand-moulds, hardened with phenolic resin, are quenched at below 300°C.
22. A process according to any one of claims 2, 12 and 14 characterized in that sand-moulds have been rendered water-repellent by treatment with silicone.
23. A process according to anyone of claims 7, 9 and 11, for aluminium or very thin-walled cast iron castings, characterized in that said sand-moulds are flushed with quenching agent during the filling operation, in that said sand-moulds, hardened with phenolic resin, are quenched at below 300°C and in that said sand-moulds have been rendered water-repellent by treatment with silicone.
24. A process according to anyone of claims 7, 9 and 11, for thick-walled iron castings, characterized in that said sand-moulds are quenched a few seconds after the filling operation in that said sand-moulds, hardened with phenolic resin, are quenched at below 300°C and in that said sand-moulds have been rendered water-repellent by treatment with silicone.
25. A process according to claim 1 or claim 2 characterized in that said sand-moulds are supported.
26. A process according to claim 1 or claim 2 characterized in that the quenching medium is used, in an enclosed system, as a means of support for said sand moulds.
27. A process according to claim 2 characterized in that said sand-moulds have been rendered water-repellent in the assembled condition.
28. A casting unit suitable for carrying out a process as defined in claim 1 comprising a quenching station adapted to quench said sand-moulds, with castings therein, during the filling operation thereof or shortly thereafter.
29. A casting unit according to claim 28 wherein said quenching station includes means for removal of said sand-moulds.
30. A casting unit according to either of claims 28 and 29 additionally comprising an impregnation station adapted to render said sand-moulds quenching-medium-repellent.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CH6513/80A CH650430A5 (en) | 1980-08-29 | 1980-08-29 | Method for casting of metals by phenolic bound sand shapes. |
| CH6513/80-9 | 1980-08-29 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1165967A true CA1165967A (en) | 1984-04-24 |
Family
ID=4310798
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000384792A Expired CA1165967A (en) | 1980-08-29 | 1981-08-28 | Process for casting metals, using sand-moulds in the form of shells |
Country Status (11)
| Country | Link |
|---|---|
| EP (1) | EP0058180B1 (en) |
| JP (1) | JPS57501828A (en) |
| BE (1) | BE890139A (en) |
| BR (1) | BR8108968A (en) |
| CA (1) | CA1165967A (en) |
| CH (1) | CH650430A5 (en) |
| DK (1) | DK190882A (en) |
| FI (1) | FI69412C (en) |
| IT (1) | IT1138537B (en) |
| PT (1) | PT73559B (en) |
| WO (1) | WO1982000786A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107427906A (en) * | 2015-04-01 | 2017-12-01 | 圣让工业公司 | For producing the arenaceous shell casting method of the part used in automobile and aviation field |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2633206B1 (en) * | 1988-06-24 | 1990-10-12 | Peugeot | MOLD FOR MANUFACTURING A METAL PART, USE OF SUCH MOLD AND CORRESPONDING MOLDING METHOD |
| FR2680125B1 (en) * | 1991-08-09 | 1995-02-17 | Peugeot | CARAPACE MOLDING METHOD AND DEVICE WITH COOLED RIGID SHELL. |
| DE10357618B4 (en) * | 2003-12-10 | 2008-01-24 | Bender, Wilfried, Dr. | Method for producing a casting from a molten metal |
Family Cites Families (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE734046C (en) * | 1941-05-20 | 1943-04-07 | Heinrich Lanz Ag | Process to prevent the penetration of moisture from the filler sand into the model sand layer in casting molds |
| FR1039893A (en) * | 1950-08-04 | 1953-10-12 | Ford | Method and apparatus for heat treatments, such as quenching castings |
| US2968848A (en) * | 1959-01-02 | 1961-01-24 | Richard T Carter | Method of casting refractory shells |
| US2985929A (en) * | 1959-12-18 | 1961-05-30 | Richard T Carter | Method and apparatus for support and cooling of shell molds |
| DE1241051B (en) * | 1961-08-12 | 1967-05-24 | Deutsche Edelstahlwerke Ag | Device for casting metallic workpieces |
| FR1351085A (en) * | 1963-03-12 | 1964-01-31 | Foundry mold | |
| US3409069A (en) * | 1966-02-01 | 1968-11-05 | Amsted Ind Inc | Method of casting steel in a shell mold |
| US3404724A (en) * | 1966-02-01 | 1968-10-08 | Amsted Ind Inc | Method of casting in a shell molding |
| JPS5638565Y2 (en) * | 1977-08-06 | 1981-09-09 | ||
| DE2806995A1 (en) * | 1978-02-18 | 1979-08-30 | Avesta Jernverks Ab | Pouring metal without turbulence into thin walled mould - gradually lowered into cooling bath during casting from horizontal into vertical position (SW 22.5.78) |
-
1980
- 1980-08-29 CH CH6513/80A patent/CH650430A5/en not_active IP Right Cessation
-
1981
- 1981-08-04 EP EP81902308A patent/EP0058180B1/en not_active Expired
- 1981-08-04 JP JP56502615A patent/JPS57501828A/ja active Pending
- 1981-08-04 WO PCT/EP1981/000110 patent/WO1982000786A1/en active IP Right Grant
- 1981-08-04 BR BR8108968A patent/BR8108968A/en unknown
- 1981-08-24 PT PT73559A patent/PT73559B/en unknown
- 1981-08-28 IT IT23692/81A patent/IT1138537B/en active
- 1981-08-28 CA CA000384792A patent/CA1165967A/en not_active Expired
- 1981-08-28 BE BE0/205805A patent/BE890139A/en not_active IP Right Cessation
-
1982
- 1982-04-28 DK DK190882A patent/DK190882A/en not_active Application Discontinuation
- 1982-09-28 FI FI823324A patent/FI69412C/en not_active IP Right Cessation
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107427906A (en) * | 2015-04-01 | 2017-12-01 | 圣让工业公司 | For producing the arenaceous shell casting method of the part used in automobile and aviation field |
Also Published As
| Publication number | Publication date |
|---|---|
| FI823324A0 (en) | 1982-09-28 |
| EP0058180B1 (en) | 1984-10-17 |
| EP0058180A1 (en) | 1982-08-25 |
| DK190882A (en) | 1982-04-28 |
| CH650430A5 (en) | 1985-07-31 |
| FI69412C (en) | 1986-02-10 |
| BR8108968A (en) | 1983-01-11 |
| PT73559A (en) | 1981-09-01 |
| FI823324L (en) | 1982-09-28 |
| IT8123692A0 (en) | 1981-08-28 |
| FI69412B (en) | 1985-10-31 |
| PT73559B (en) | 1983-01-17 |
| JPS57501828A (en) | 1982-10-14 |
| WO1982000786A1 (en) | 1982-03-18 |
| IT1138537B (en) | 1986-09-17 |
| BE890139A (en) | 1981-12-16 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |